Carton with plastic reclosable header

ABSTRACT

The disclosure relates to a method and apparatus for manufacturing a package with a rigid or semi-rigid container and a polymeric or plastic header with a reclosure, such as a zipper. The rigid or semi-rigid container is typically provided in a stack of flat containers. The header is sealed, glued or otherwise secured to the containers. The container, typically inverted, is filled, and the bottom is formed by folding and sealing the bottom portion of the container.

This application claims priority under 35 U.S.C. §119(e) of provisionalpatent application Ser. No. 61/249,852, filed on Oct. 8, 2009 andprovisional patent application Ser. No. 61/298,429, filed Jan. 26, 2010,the contents of both of which are incorporated by reference in theirentirety.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The present disclosure relates to a method and apparatus for producing apackage with a carton-type container made from paper, cardboard,chipboard or similar rigid or semi-rigid material with attached theretoa reclosable header section made from plastic, polymer or other flexiblematerial, the reclosable structure being typically a zipper, but notlimited thereto. The present disclosure likewise relates to theresulting package.

2. Description of the Prior Art

In the prior art, it is known to make reclosable flexible plastic bagsfor the sale of foodstuffs or other consumer products. The bags orpackages, while well suited for their intended uses, have typically notbeen used for food products that would easily be crushed or damagedduring shipment. Additionally, such bags or packaging can result ininefficiencies in storage, transportation and display.

Likewise, traditional cardboard boxes are well-known for the packagingand marketing of such well-established products as cereal. However,these boxes typically are heavy and require an internal waxed paper orsimilar liner, typically tearable and therefore not resealable and donot protect the contents after initial opening. This increasesmanufacturing costs and typically does not allow the package to befilled completely with product, thereby resulting in inefficiencies inspace, which increases the costs for storage, transportation and displayof the product. Therefore, many of these traditional cardboard boxes,particularly those with a tearable plastic liner, have been less thansatisfactory in their reclosable capabilities.

There have been several attempts at packages to address thesedeficiencies, but none have been entirely satisfactory. These previousattempts include those disclosed in U.S. Pat. No. 7,524,111 entitled“Rigid-Bottomed. Resealable Bag with Handles”, issued on Apr. 28, 2009to Williams; U.S. Pat. No. 7,207,716 entitled “Flexible Container HavingFlat Walls”, issued on Apr. 24, 2007 to Buchanan; U.S. Pat. No.7,160,029 entitled “Enclosure for Resealing a Package and MethodTherefor”, issued on Jan. 9, 2007 to Bein; U.S. Pat. No. 6,908,422entitled “Reclosable Packaging Bag and Method for Manufacturing Same”,issued on Jun. 21, 2005 to Ichikawa et al.; U.S. Pat. No. 6,110,512entitled “Package and Merchandiser”, issued on Aug. 29, 2000 toTeasdale; U.S. Pat. No. 6,063,416 entitled “Procedure and Package toEnable Peg Display of Food Pouch in Tent-Style Paperboard Carton”,issued on May 16, 2000 to Teasdale et al.; U.S. Pat. No. 4,691,373entitled “Zipper Closure with Unitary Adhesive Cover Sheet”, issued onSep. 1, 1987 to Ausnit; and U.S. Published Patent Application No.2005/0194386, entitled “Zipper Box Covers” published on Sep. 8, 2005 forShai; and Japanese Patent No. 2002104511 entitled “Bag-in-Carton”,published on Apr. 10, 2002 for Makoto et al.

SUMMARY AND OBJECTS OF THE DISCLOSURE

It is therefore an object of the present disclosure to provide areclosable package which has rigid walls thereby providing a highcapacity, space-efficient package with a flat printing surface therebyproviding protection for the packaging of crushable or delicateproducts.

It is therefore a further object of the present disclosure to provide apackage which is light in weight and which is typically reclosable.

These and other objects are attained by the present disclosure byproviding a package, along with a method and apparatus for theproduction thereof, which includes a rigid or semi-rigid carton-typecontainer and, attached thereto, a plastic, polymer, or similar flexibleheader, typically with a reclosable zipper configuration, but notlimited thereto.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects and advantages of the disclosure will become apparentfrom the following description and from the accompanying drawings,wherein:

FIG. 1 is a perspective view of an embodiment of a package of thepresent disclosure, shown in a filled configuration with a sealed bottomand an upwardly projecting header.

FIG. 2 is a perspective view of an embodiment of a package of thepresent disclosure, shown in a filled configuration with a sealed bottomand a flush header.

FIG. 3A is a plan front view of an embodiment of a package of thepresent disclosure, shown in a flat, unfilled configuration, with anupwardly projecting header and an unsealed bottom.

FIG. 3B is a cross-sectional view of typical material used for the rigidor semi-rigid container portion of embodiments of the presentdisclosure.

FIG. 3C is a perspective view showing the header attached to theinterior of the container portion of the package.

FIG. 4A is a plan view of an embodiment of an inverted package of thepresent disclosure, showing the bottom partially folded, typically afterbottom filling, with the bottom fin seal pointing upwardly.

FIG. 4B is a plan view from above of the embodiment of the invertedpackage of FIG. 4A.

FIG. 5A is a plan view of an embodiment of an inverted package of thepresent disclosure, showing the bottom partially folded, typically afterbottom filling, with the bottom fin seal folded flush with the bottom ofthe package.

FIG. 5B is a plan view from above of the embodiment of the invertedpackage of FIG. 5A.

FIG. 6A is a plan view of an embodiment of an inverted package of thepresent disclosure, similar to FIG. 1, showing the ears of the bottomfolded against the sides of the package and sealed thereto, typicallyafter bottom filling.

FIG. 6B is a side plan view of the embodiment of the inverted package ofFIG. 5A.

FIG. 6C is a bottom view of an embodiment of the package, shown with theears folded and sealed to the bottom of the package.

FIG. 6D is a cross-sectional view of an embodiment of the package, shownwith flaps on the front and rear panels for the interior attachment ofthe header portion.

FIG. 6E is a side view of a further embodiment of the package of thepresent disclosure.

FIG. 6F is a perspective view showing the embodiment of the package ofFIG. 6E, with a folded header.

FIG. 6G is a side view of a still further embodiment of the package ofthe present disclosure.

FIG. 6H is a perspective view showing the embodiment of the package ofFIG. 6G, with a folded header.

FIG. 7 is a perspective view of the top of the rigid or semi-rigidcontainer portion of an embodiment of the package of the presentdisclosure, showing a radius or chamfer formed at the corners thereof.

FIG. 8A is a schematic view of a first embodiment of a method andapparatus for producing the package of the present disclosure prior tofilling.

FIG. 8B is a schematic view of a second embodiment of a method andapparatus for producing the package of the present disclosure prior tofilling, further including a portion in phantom for illustrating a stillfurther variation.

FIG. 8C is a schematic view of a third embodiment of a method andapparatus for producing the package of the present disclosure prior tofilling.

FIG. 8D is a schematic view of a fourth embodiment of a method andapparatus for producing the package of the present disclosure prior tofilling.

FIG. 8E is a schematic view of a fifth embodiment of a method andapparatus for producing the package of the present disclosure prior tofilling.

FIG. 8F is a schematic of view of a sixth embodiment of a method andapparatus for producing the package of the present disclosure prior tofilling.

FIG. 8G is a side view of the sixth embodiment (see FIG. 8F) of a methodand apparatus for producing the package of the present disclosure priorto filling.

FIG. 9A is a schematic view of a seventh embodiment of a method andapparatus for producing the package of the present disclosure prior tofilling.

FIG. 9B is a schematic view of an eighth embodiment of a method andapparatus for producing the package of the present disclosure prior tofilling.

FIG. 9C is a schematic view of a ninth embodiment of a method andapparatus for producing the package of the present disclosure prior tofilling.

FIG. 10 is a perspective view of an embodiment of the ultrasonicapparatus used to form the cross-seals in an aspect of an embodiment ofthe method and apparatus for producing the package.

FIG. 11 is a perspective view of an ultrasonic apparatus used to formthree cross-seals simultaneously in an aspect of an embodiment of themethod and apparatus for producing the package.

FIG. 12 is a schematic of an embodiment of method and apparatus of thepresent disclosure for bottom filling and sealing the packages.

FIG. 13 is a top view of a band sealer used for forming the bottom finseal in an aspect of an embodiment of the method and apparatus of thepresent disclosure.

FIG. 14 is a side view of the band sealer of FIG. 13 forming a bottomfin seal for an inverted package in an aspect of an embodiment of themethod and apparatus of the present disclosure.

FIG. 15A is a plan view of an embodiment of the package of the presentdisclosure, showing two alternative handle positions.

FIG. 15B is a perspective view of an embodiment of the package of thepresent disclosure, showing a handle built into the header.

FIG. 16 is a plan view of a header of an embodiment of the package ofthe present disclosure, wherein the header is opened by a perforatedline or similar line of weakness.

FIG. 17A is a plan view of a header of an embodiment of the package ofthe present disclosure, wherein the header is opened by way of apre-activated peel seal.

FIG. 17B is a plan view of discrete zipper segments on a length of webmaterial.

FIG. 18 is a top plan view of a triangular rigid or semi-rigid portionof an embodiment of the package of the present disclosure, therebyallowing for improved pouring from the package in some instances.

FIG. 19A is a perspective view of a header of an embodiment of thepackage of the present disclosure, wherein the zipper extends onlypartially across the top of the header.

FIG. 19B is a perspective view of a header of an embodiment of thepackage of the present disclosure, wherein a shortened zipper isprovided across a portion of the top of the header.

FIG. 20 is a plan view of a header of an embodiment of the package ofthe present disclosure, showing the zipper providing access to a pourspout.

FIG. 21A is a diagram of embodiment of the package of the presentdisclosure, wherein the package is filled between the container and theweb of the header material.

FIG. 21B is a diagram of an embodiment of the package of the presentdisclosure, wherein the package is filled between the zipper and theheader.

FIG. 21C is a diagram of an embodiment of the package of the presentdisclosure, wherein the package is filled between the zipper profiles.

FIG. 22 is a diagram of several variations of an embodiment of thepackage of the present disclosure, wherein a straw aperture is formed inthe header, the header is provided with a tear-away compartment withprinted material, and wherein the side of the carton includes areinforcing member.

FIG. 23 is a plan view of a header with a slider zipper and a tear-awayportion.

FIG. 24 illustrates an embodiment of the package of the presentdisclosure with a cap placed over the top of the package.

FIG. 25 illustrates an embodiment of the package of the presentdisclosure with a reinforcing band placed around the package.

FIG. 26 illustrates an embodiment of the package of the presentdisclosure, which is free of gussets and includes a diagonally orientedzipper spanning opposing corners of the container portion.

FIGS. 27A-27I illustrate various zipper and web material cross sectionswhich may be used in embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail wherein like numerals indicatelike elements throughout the several views, one sees that FIG. 1 is aperspective view of an embodiment of the package 10 of the presentdisclosure. Package 10 includes a rigid, semi-rigid or fibrouscarton-type container 12, typically with a central layer 164 (FIG. 3B)made from a paper product such as fiberboard or chipboard and aninterior surface 166 with an oxygen barrier and a moisture barrier and apoly-coated outer layer 162, but is not limited thereto (hereinafter,collectively referred to as a “semi-rigid container”). Semi-rigidcontainer 12 is typically initially provided in a flat configuration asshown in FIG. 3A with an open top or mouth 14 and an open bottom 16.Package 10 further includes a plastic or polymeric header 18 (typicallyapplied by heat, adhesive or glue) which includes first and secondsidewalls 20, 22 and a reclosure (or closure) 24, illustrated as azipper with first and second interlocking profiles 25, 27 (see FIG. 6B),but is not limited thereto. Other examples of reclosures include, butare not limited to, flanged zippers with opening lips, flangedtamper-resistant zippers, tamper-evident zippers, flanged zippers withsliders (see FIG. 23), flanged zippers without sliders, string(flangeless) zippers, double zippers (see FIG. 27I), multiple trackzippers, zippers with a tear line, a zipper with flanges connected abovethe locking elements, zippers with flanges connected below the lockingelements, leak-resistant zippers, zippers with a peel seal, hingedzippers, zippers with spot seals, zippers with eyemarks, partly sealedzippers, zippers with shape-retaining characteristics, pinch grip pullzippers (i.e., lower product side opening strength than consumer sideopening strength), zipper tape (especially for applications involvingfrozen foods), hook-and-eye (i.e., Velcro®), reclosable adhesives,perforated cap zipper tape, laminated zipper tape with a tear bead,zippers with a weakened line of resistance, zippers with a wedge,zippers with a stabilizing post, zippers with guide ribs, zippers with acompression post, and fitments. These terms are known to those skilledin the art, and the corresponding zippers are disclosed in patentsincorporated by reference in their entirety hereinafter. Additionally,in some applications, a peel seal may be substituted for the reclosure.Similarly, examples of the web from which header 18 is manufacturedincludes, but are not limited to, film with eyemarks, printed film (seeFIG. 22), film with cut-outs, film with diagonal seals and film withtear-lines. The header 18 is sealed or glued to the mouth 14 ofsemi-rigid container 12. First and second cross-seals 21, 23 or othermethods of attachment are formed at the ends of header 18 between thesidewalls 20, 22, immediately outwardly adjacent from first and secondfolded edges (or first and second exterior folds) 30, 32. The first andsecond cross-seals 21, 23 further typically include respective first andsecond side incisions or notches 31, 33 in order to remove material toaid in the subsequent folding of the header 18 into the position shownin FIG. 2. Other shapes, such as single or multiple radius cut-outs arealso envisioned. It is noted that it is envisioned that someapplications may fold the header 18 onto the top of the package 10.However, it will be preferred in many applications that the reclosure orzipper 24 not be bent 180 degrees. The header 18 may be made withbio-degradable plastic. Additionally, in such an embodiment, the sealantfor semi-rigid container 12 would also be made bio-degradable.

As shown in FIG. 3A, semi-rigid container 12 is typically initiallyprovided in a flat state with front panel 13 and rear panel 15.Semi-rigid container 12 is typically partially or fully poly-coated onexterior surface 162 (FIG. 3B), particularly in the areas where heatsealing is required, such as the top of semi-rigid container 12 whereheader 18 is attached, and the portions of semi-rigid container 12 wherethe bottom is sealed shut before or after filling. Alternately, adhesiveis applied in the required areas and the attachment is done by theseadhesives. Additionally, interior coating or lamination may includeother materials required for the necessary barrier properties, includinghermeticity and oxygen-moisture barriers. While illustrated in FIG. 3A(see FIG. 22), front and rear panels 13, 15 typically have printingincluding advertising and product information in text and graphics formon the exterior thereof, such as most products commonly found in agrocery store or other retail establishment. Front panel 13 and rearpanel 15 are joined to each other by first and second folded edges 30,32 which ultimately become the central folds of the first and secondgusseted sides 34, 36 of semi-rigid container 12 in the expanded orfilled configuration as shown in FIGS. 1 and 2. Front panel 13 ofsemi-rigid container 12 further includes first and second front interiorvertical folds 38, 40 which are inwardly adjacent from and parallel tofirst and second folded edges 30, 32. In the expanded or filledconfigurations as shown in FIGS. 1 and 2, first and second frontinterior vertical folds 38, 40 form the transition from the frontsurface 42 to the gusseted sides 34, 36. Similar first and second rearinterior vertical folds 38′, 40′ are formed on the rear of thesemi-rigid container 12, see FIGS. 5A and 5B, forming the transitionfrom the rear surface 43 to the gusseted sides 34, 36. As shown in FIG.7, as well as FIG. 3A, the upper ends of vertical folds 38, 38′, 40, 40′may terminate in chamfered sections 39, 39′, 41, 41′, respectively, inorder to prevent cracking of the material of semi-rigid container 12during folding and further to reduce the likelihood of the material ofsemi-rigid container 12 forming a point to puncture the material ofheader 18. Similarly, as shown in FIG. 7, in order to prevent leakagebetween header 18 (not shown in FIG. 7) and semi-rigid container 12,extra dots of glue (indicated as “G”) are provided at the top of firstand second folded edges 30, 32 within first and second gusseted sides34, 36. Additionally, as semi-rigid container 12 is typically formedfrom a single sheet of material with a seam 35 formed at the overlappingjoinder of the edges (shown in FIG. 7 as occurring at second interiorvertical fold 40) an extra dot of glue (indicated as “G′”) is providedat the top of seam 35 in order to prevent leakage between the semi-rigidcontainer 12 and the header 18 due to the transition in thickness causedby seam 35. Other embodiments may use an even number (four or greater)of panels.

Returning to FIG. 3A, one sees that first and second interior horizontalfolds 46, 48 are formed on front panel 13 adjacent to the bottom 16.Similar first interior horizontal fold 46′ is formed on the rear panel15 of semi-rigid container 12, see FIGS. 5A, 5B. The first interiorhorizontal folds 46, 46′ are used to form the transition to the bottomsurface 50 while the second interior horizontal fold 48 is used to formthe fin seal 52 as shown in FIGS. 4A, 4B, 5A and 5B. A second horizontalfold is not illustrated on the rear panel 15, as typically, only one ofpanels 13, 15 include a second horizontal fold in order to help forcethe fin seal 52 to fold in a specific direction. As shown in the area ofdetail of FIG. 3A, the lower portions of first and second front interiorvertical folds 38, 40 form respective first and second inwardly inclinedfold portions 139, 141. As shown in the area of detail of FIG. 3A, anangle of typically 1-4 degrees, or preferably 2-3 degrees in mostapplications, is formed between the projection of respective frontinterior vertical folds 38, 40 (with substantially identicalconstruction on the rear of semi-rigid container 12) and inwardlyinclined fold portions 139, 141, so that the inwardly inclined foldportions 139, 141 incline or veer toward the center of the semi-rigidcontainer 12 as the inwardly inclined fold portions 139, 141 approachthe open bottom 16. This aids in the subsequent folding of thesemi-rigid container 12 into the package 10.

As further shown in FIG. 3A, corresponding first and second oval-shapedpartially scored portions 47, 49 (typically cutting through a firstlayer of a multi-laminate or coated surface, however other similarmethods, such as compressing, are considered to be within the definitionof scoring) are formed with a vertical major axis on semi-rigidcontainer 12 immediately below header 18, outwardly adjacent from firstand second front interior vertical folds 38, 40 (thereby being locatedwithin the gusseted sides after the package 10 has been formed). Duringthe formation of the package 10 from the semi-rigid container 12 andheader 18, corresponding first and second oval-shaped dots of glue 51,53 (with a horizontal major axis) are placed on one side of front ofheader 18, typically above reclosure or zipper 24 and inwardly adjacentfrom respective first and second cross-seals 21, 23. Additionally, a dotof glue 55 may be placed just below the mid-point of the top edge ofheader 18. Typically, hot melt glue is used, but other glues oradhesives may be applicable to various applications. During formation ofthe package 10 from the semi-rigid container 12 and header 18, theheader 18 is folded down against the sides of the formed semi-rigidcontainer 12 so that first and second oval-shaped dots of glue 51, 53cover and are glued or otherwise secured to respective first and secondoval-shaped partially scored portions 47, 49. Similarly, dot of glue 55tacks the top edge of header 18 against the folded-down sidewall 20.Thereafter, when the user lifts the header 18 so as to break theconnection formed by first and second oval-shaped dots of glue 51, 53,typically only the relatively well-defined first and second oval-shapedpartially scored portions 47, 49 are torn from the semi-rigid container12, with little or no unsightly fiber tears. First and secondoval-shaped partially scored portion 47, 49 are typically provided onlyon the front of semi-rigid container 12. Otherwise, the front and rearviews of semi-rigid container 12 are substantially identical.Alternately, releasable configurations may be used to attach the foldedheader to the sides of the formed semi-rigid container, such as, but notlimited to, releasable adhesives, hook-and-eye (Velcro®), multiplestrips, etc.

First diagonal fold 54 extends from the intersection of first interiorvertical fold 38 and first horizontal fold 46 to the intersection offirst folded edge 30 and second horizontal fold 48. Similarly, seconddiagonal fold 56 extends from the intersection of second interiorvertical fold 40 and first horizontal fold 46 to the intersection ofsecond folded edge 32 and second horizontal fold 48. Additionally, asshown in FIG. 3A, the lower corners are removed by first and secondlower cuts 57, 59 which extend diagonally from the respective ends ofsecond horizontal fold 48 to opposite ends of the bottom 16 of thesemi-rigid container 12. This results in diagonal ends on fin seal 52 asshown in FIG. 4A. As shown in FIGS. 4B, 5B and 6B, similar first andsecond diagonal folds 54′, 56′ are formed on the rear panel 15 ofsemi-rigid container 12. The first and second diagonal folds 54, 54′,56, 56′ are necessary for forming the diagonal edges of first and secondlower triangular ears 58, 60, shown in the transitory extended positionin FIGS. 4A, 4B, 5A, 5B and shown in the final sealed flush position inFIGS. 1, 2, 6A and 6B.

FIGS. 6E and 6F illustrate a further embodiment of package 10, whereinfirst and second sidewalls 20, 22 may be provided as two separate sheetsor a single sheet, and wherein seal 119 either joins the two separatesheets or is formed in a central location on the single sheet. Sidewall20 includes a line of weakness 72 (which may include perforations, laserscored lines, tear beads, tear notches, linear tear lines, a peel seal,or similar structures, and may be configured as multiple lines) withfirst and second flanges 25′, 27′ of zipper 24 extending over line ofweakness 72 and sealed to first sidewall 20 on opposite sides of line ofweakness 72. Zipper 24 further includes an opening zipper flange 123extending therefrom. In this position, the zipper 24 is placed on thefront of the header 18, in an off-central rather than central position.A similar alternative embodiment would attach the zipper 24 on theinterior of first side wall 20.

FIGS. 6G and 6H illustrate a still further embodiment of package 10wherein the sidewalls 20, 22 are provided as separate sheets (oralternately, as a single sheet with an opening or tear linetherethrough) and flanged zipper 24 with slider 70 is sealed to theexterior thereof (first flange 25′ sealed to sidewall 20 and a secondflange 27′ sealed to sidewall 22) thereby allowing the consumer tooperate the slider 70 to open the zipper 24 and thereby gain access tothe contents of the package 10.

FIGS. 8A-14 illustrate methods and apparatus for producing the packages10 of FIGS. 1-7. FIGS. 8A-G and 9A-C illustrate methods and apparatusfor producing the unfilled flat packages of FIG. 3A. In FIG. 8A (withmany similar elements shown in the subsequent figures), a stack 11 ofpre-made or previously made folded semi-rigid containers 12 is providedto a sequential feeder 290 (other sequential feeding apparatus, such asan upstream conveyor or pick-and-place apparatus, may be substituted forthe stack 11 and sequential feeder 290), and the semi-rigid containers12 are fed sequentially in a machine direction by a servo-drivenconveyor 103. Web material 102 is provided from a spool 100, withperiodic eyemarks 104 (in some applications, cut-outs in the webmaterial could be substituted for eyemarks), the detection of which byeye-mark detector 111 is used to time the sequential feeding ofsemi-rigid containers 112 by sequential feeder 290 to conveyor 103 (theregistration provided by the eyemarks 104 and the detection thereof istypically only required if the web material 102 has graphics or otherprinting with defined locations for the beginning and end of adjacentheaders, see FIG. 22). Alternatively, the detection of the periodiceyemarks 104 can be used to vary the speed of the conveyor 103 so thatthe semi-rigid containers are delivered with the correct registrationwith respect to the web material 102. Length of zipper material 202 isprovided from spool 200 and is sealed to length of web material 102 atsealing and folding station 106 (length of zipper material 202 may beconfigured without sliders, with pre-mounted sliders, or with slidersmounted by optional slider mounting station 204 shortly after the zipperis provided from spool 200 or mounting station 204′ can be located afterthe zipper material is attached to the web material as shown in FIG.8A). This sealing may be done by attaching a first flange of aninterlocked zipper material 202 to unfolded web material 102 and thenattaching the second flange after the web material 102 is folded aroundthe zipper material 202. Alternately, the separate, unlocked profiles ofzipper material 202 may be attached to the web material 102 and the webmaterial 102 thereafter folded so that the profiles of zipper material202 are aligned and interlocked (see the alternative embodimentillustrated in phantom in FIG. 8B). In another alternative, theinterlocked zipper material 202 may be introduced between a folded webmaterial 102 and then sealed or attached thereto. In yet anotherembodiment of the method, the zipper is attached to separate webmaterials. In such an embodiment, the zipper is either attached to oneweb in an unlocked condition, one section to each web, and thereafter,the zipper is aligned and interlocked or one side of an interlockedzipper material can be attached to one web material. Then the other webmaterial can be attached to the other side of the zipper material. Inthese embodiments, the zipper can be separated at a later stage forfilling the semi-rigid container through the zipper. Additionally, whilethe preferred method of attaching together the zipper, web, andsemi-rigid containers requires several steps, this may be done in fewersteps or even simultaneously.

Typically, releasable dots of glue (other similar methods may be used)are applied to the length of web material at glue station 107 for thepurpose of attaching the header 18 to the outside of formed semi-rigidcontainer 12. At web sealing (or attaching) station 108, the length ofweb 102 (with the zipper 202 attached thereto) is folded (the lateraledges of which thereby form first and second sidewalls 20, 22 of header18 of FIGS. 1-6) so as to contact semi-rigid containers 12. The lateraledges of web material 102 are glued, sealed or otherwise fastened tofront and rear panels 13, 15 of semi-rigid container 12 by web sealingor attaching station 108. Sealing station 108 typically includescompression rollers and a heated bar on both sides of the web. Thesealing station may include multiple heated seal bars, wherein thesemi-rigid container 12, with the header 18 in position, passes throughthese heated bars with little to no contact pressure. After each set ofseal bars, the container 12 and header 18 pass through compressionrollers. The compression rollers set the film-to-film seal (i.e.,cross-seals 21, 23) between the semi-rigid containers 12 and thefilm-to-container seal over the containers 12. These compression rollerscan be free-spinning or driven. Additionally, it has been found that bypre-tensioning the film of header 18 during sealing, that the package 10becomes more rigid. The semi-rigid containers 12 with the web material102 attached (with the zipper material 202, in turn, attached to webmaterial 102) move in the machine direction. A cross-sealer 110 withtypically three cross-seal bars 112, 114, 116 (see FIG. 11) reciprocatesso that it momentarily travels in the machine direction, tracking themovement of the semi-rigid containers 12 and the web material 102 (withzipper material 202 attached thereto), and engages the web material 102so that a first cross-seal 21 and adjoining second cross-seal 23 of anadjacent package are simultaneously formed in three successiveinter-package gaps, typically without the necessity of slowing orstopping the travel of web material 102. The use of multiple cross-sealbars (typically ultrasonic, but may include heat welding) along with thesynchronized travel with the web material 102 allows for a prolongeddwell time, thereby improving sealing qualities, while maintaining highproduction rates. In some embodiments, a lesser or greater number ofcross-seal bars may be implemented. The cross-sealer 110 then travels inthe opposite direction from the machine direction to position itself forthe cross-sealing operation with the successive or consecutive threeinter-package gaps. The cross-seal bars 112, 114, 116 typically includea reverse knurled ultrasonic horn and a reverse knurled ultrasonic anvilas shown in FIG. 10. The reverse knurled surface creates a multitude ofsmall pockets for the polymeric or similar material to flow during thesealing or welding of the cross-seals 21, 23. This produces high qualityand aesthetically appealing cross-seals in half the time of heat andpressure sealing. It also typically removes the ambient heat thatdamages film during long machine stops. FIGS. 8A-G and 9A-C illustratemethod and apparatus of attaching zipper web material to the outside offolded semi-rigid containers 12. However, such zipper material can beattached to the inside of the semi-rigid containers 12. In such anembodiment, the edges 30, 32 of gussets 34, 36 are slit a requireddistance, and the zipper web material is introduced between theseparated upper portions of gussets 34, 36 and attached thereto and topanels 13, 15. Alternatively, as shown in FIG. 6D, panels 13, 15 (aswell as gussets 34, 36) are provided with upwardly facing flaps 13′, 15′between and to the inside of which zipper web material forming header 18is attached as in FIG. 3C.

The web material 102 in the inter-package gaps is then severed bycutting station 120, resulting in the flat and unfilled packages 10 ofFIG. 3A. Alternately, in lieu of cutting, perforations can be made inthe cross-seals by station 120, thereby leaving the packages in aconcatenated chain.

FIG. 8B shows a similar method and apparatus, wherein no eyemarks areprovided on the web material 102 (typically because no graphics areprovided on the web material 102 which would require criticalregistration) and wherein the conveyor 103 is a servo-driven chain withperiodically spaced adjustable lugs 105 for engaging the trailing edgesof semi-rigid containers 12 thereby assuring accurate spacing of thesemi-rigid containers 12. Further illustrated in FIG. 8B, in phantom, isa second source of zipper material 200B, wherein source 200 wouldinclude a first interlockable profile and source 200B would include asecond interlockable profile. The separate, unlocked profiles of zippermaterial 202 may be attached to the web material 102 and the webmaterial 102 thereafter folded so that the profiles of zipper material202 are aligned and interlocked

As shown in FIG. 8C, another alternative is to provide two separatesheets of web 102A, 102B. Zipper profiles 202A, 202B are supplied fromrespective spools 200A, 200B and sealed to sheets of web 102A, 102B bysealing stations 106A, 106B. The zipper profiles 202A and 202B are thenaligned and joined together and the top edges of the sheet web 102A,102B sealed together at a joining and sealing station 109. However, ifat a later stage, the then-formed container is to be filled through thezipper, the top edges 102A and 102B are left unsealed.

As shown in FIG. 8D, another alternative is to feed two sheets of web102A, 102B and interlocked zipper 202 to sealing station 106 wherein afirst profile of zipper 202 is sealed to web 102A and a second profileis sealed to web 102B simultaneously or at a later station. Again,however, if at a later stage, the then-formed container is to be filledthrough the zipper, the top edges 102A, 102B are left unsealed. The topedges of sheets of web 102A, 102B are then sealed together at sealingstation 109. FIG. 27H is a representative cross section of what may beproduced by this method and apparatus, showing, in particular, lines ofweakness 72 or similar opening structure (which may includeperforations, laser scored lines, tear beads, tear notches, linear tearlines, a peel seal, or similar structures, and may be configured asmultiple lines) formed in sidewalls 20, 22 thereby providing access tozipper 24 after removal of removable header portion 29. Furtherillustrated in FIG. 27H is pocket 133 formed between seals 135, 137 thatcan hold printed advertising or similar material 138 therein. Thisstructure is likewise illustrated in FIG. 22.

As shown in FIG. 8E, segments of zipper material, resulting in discretezippers 24, may be fed to the length of web material 102 by zipperfeeder 206 as shown in FIG. 17B resulting in a spaced-apartconfiguration. This may avoid having the zipper profile in cross-seals21, 23, but requires accurate registration of the zippers 24 withrespect to the web material 102. In this embodiment, the zipper segmentsmay be applied to web material 102 in line with the web direction or atan angle to it.

As shown in FIGS. 8F and 8G, stack 11 is implemented as a magazine withcontainers 12 stacked vertically therein. Sequential feeder 290 isimplemented as a conveyor belt. Conveyor belt 290 pulls a singlecontainer 12 through a feed gate which allows only the thickness of onebox to pass through. Containers 12 are then engaged in a nip formedbetween upper and lower conveyor pull belts 292, 294. The upper andlower conveyor pull belts 292, 294 are typically set at a speeddifferent than that of the conveyor belt 290 in order to control the gapbetween successive containers 12. The edge of containers 12 is sensed byelectric eye 296 which controls the operation of glue dot applicator 502(similar to that shown in FIG. 9C) which applies glue dots to thecontainers 12.

FIGS. 9A and 9B disclose methods and apparatus similar to those of FIGS.8A and 8B, except that web material 102 is supplied with the length ofzipper material 202 already sealed thereto. If the web material 102 isprovided in a folded state, then folding within the illustratedapparatus is not required.

FIG. 9C discloses a method and apparatus wherein the length of webmaterial 102 is supplied with the length of zipper 202 already attachedthereto. The length of web material 102 is fed in open configuration ata right angle (i.e., perpendicularly) to the direction of travel of thesemi-rigid containers 12. The length of web material 102 (with zipper202 attached) is then brought into alignment with the direction oftravel of semi-rigid containers by roller 500. Glue spots are applied byapplicator 502 and guiding rollers 504, 506, 508 fold the web material102 over the succession of semi-rigid containers 12.

Typically, the resulting header 18 comprises web reclosure material,wherein the distance between the edges of the header 18, when spreadapart, is greater than the distance between the edges of the sides ofthe semi-rigid container 12 when the semi-rigid container 12 is unfoldedand formed (i.e., the distance between first and second front interiorvertical folds 38, 40).

FIGS. 27A-27I illustrate various embodiments or variations of the zipper24, including profiles 25, 27, with respect to their attachment to frontand rear sidewalls 20, 22 of web material 102, as well as differentconfigurations of web material 102 as in FIGS. 27E and 27F. It should benoted that FIGS. 27A, 27E and 27F relate to constructions where thezipper is attached to the outside of the folded web material (also seeFIGS. 6E and 6G). As stated previously, many different kinds of zipperscan be used, such as hinged zippers, slider zippers, flangeless (string)zippers and any of the zippers disclosed in U.S. Pat. No. 6,360,513entitled “Resealable Bag for Filling with Food Product(s) and Method”,to Strand et al.; U.S. Pat. No. 7,137,736 entitled “Closure Device for aReclosable Pouch” to Pawloski; U.S. Pat. No. 5,972,396 entitled“Flexible Package Having a Reclosable Zipper” to Jurgovan; U.S. Pat. No.6,030,122 entitled “Pinch-Grip Zipper” to Ramsey; U.S. Pat. No.6,347,885 entitled “Reclosable Package Having Zipper Closure, SliderDevice and Tamper-Evident Structure” to Buchman; U.S. Pat. No. 6,427,421entitled “Method of Manufacturing Recloseable Packages” to Belmont; U.S.Pat. No. 4,846,585 entitled “Easy Open Bag Structure” to Boeckmann; U.S.Pat. No. 4,874,257 entitled “Method of Forming a Closed Filled Bag, aBag Construction and an Apparatus for Forming the Bag” to Inagaki; U.S.Pat. No. 6,299,353 entitled “Zipper for Reclosable Container withApertures Passing Through Female Profile” to Piechocki; U.S. Pat. No.6,955,465 entitled “Powder-Resistant Flexible Zipper For ReclosablePackaging” to Machacek; U.S. Pat. No. 7,241,046 entitled “WatertightClosure for a Reclosable Package” to Piechocki; U.S. Pat. No. 6,609,827entitled “Bag Having Slider-Actuated Complementary Closure Strips and aLeakproofing Structure” to Bois et al.; U.S. Pat. No. 3,325,084 entitled“Pressure Closable Fastener” to Ausnit; U.S. Pat. No. Re. 34,554entitled “Bags with Reclosable Plastic Fastener Having Automatic SealingGasket Means” to Ausnit; U.S. Pat. No. 5,520,463 entitled “FoamedZipper” to Tilman; U.S. Pat. No. 4,787,880 entitled “Method of MakingExtruded Zipper Strips and Bags Containing the Same” to Ausnit; U.S.Pat. No. 6,177,172 entitled “Zippered Film and Bag” to Yeager; U.S. Pat.No. 6,021,557 entitled “Process of Making a Zipper for a ReclosableThermoplastic Bag” to Dais et al.; U.S. Pat. No. 7,478,950 entitled“Variable Alignment Slider Zipper for Reclosable Bags” to Plourde etal.; U.S. Pat. No. 4,925,316 entitled “Reclosable Bag Having an OuterReclosable Zipper Type Closure and Inner Non-Reclosable Closure” to VanErden et al.; U.S. Pat. No. 4,923,309 entitled “Tamper-Evident Package”to Van Erden; U.S. Pat. No. 5,509,734 entitled “Wedge Activated Zipper”to Ausnit; U.S. Pat. No. 4,736,451 entitled “Extruded Zipper HavingCombination Stabilizing and Differential Opening Means” to Ausnit; U.S.Pat. No. 5,412,924 entitled “Method of Making Reclosable Plastic Bags ona Form, Fill and Seal Machine” to Ausnit; U.S. Pat. No. 3,959,856entitled “Interlocking Separable Fastener” to Ausnit; U.S. Pat. No.6,131,370 entitled “Zipper Applied Across a Film in TransverseDirection” to Ausnit; U.S. Pat. No. 6,863,754 entitled “Apparatus andMethod for Manufacturing Reclosable Bags Utilizing Zipper Tape Material”to Wright et al.; U.S. Pat. No. 6,290,392 entitled “Reclosable PlasticBag with Deformable, Stay-Open Inlay” to Sandor; U.S. Pat. No. 3,054,434entitled “Bag Closure” to Ausnit; U.S. Pat. No. 4,665,552 entitled“Zipper Equipped Bags and Method of and Means for Manually Filling andSeparating Them” to Lems et al.; U.S. Pat. No. 5,902,427 entitled“Fastener Arrangement with Dual Purpose Cover Sheet” to Zinke et al.;U.S. Pat. No. 5,174,658 entitled “Self-Expanding and Reclosable FlexiblePouch” to Cook et al.; U.S. Pat. No. 6,827,491 entitled “Wide OpenFeature for Reclosable Bags” to Kohl et al.; U.S. Pat. No. 6,899,460entitled “Storage Bag with Openly Biased Mouth” to Turvey et al.; andU.S. Pat. No. 6,167,597 entitled “High Compression Zipper” to Malin, thecontents of all of which are hereby incorporated by reference in theirentirety.

A typical bottom filling method and apparatus is shown in FIG. 12. It isimportant to note that the filling apparatus and machinery shown in FIG.12 may be geographically or otherwise spatially separated from thepackage forming machinery of FIGS. 8A-G and 9A-C. The forming andfilling operations may take place at separate times and places, at thesame time and place. The forming and filling apparatus and machinery maybe on separate manufacturing lines or on an integrated manufacturingline. The package of FIG. 3A (resulting from the method and apparatus ofone of FIGS. 8A-G and FIGS. 9A-C) is inverted. Former 300 opens up thepackage 10 so that first and second interior vertical folds 38, 38′, 40,40′ become the corners of the semi-rigid container 12, and a productvolume is created within the semi-rigid container 12. This typicallyincludes applying opposing forces on the semi-rigid container 12 nearcross seals 21, 23 as illustrated by the arrows labeled “F” on the farleft of FIG. 12. At first sealer 302 (alternatively characterized as areleasable attacher), as explained with respect to FIG. 3A, first andsecond oval-shaped dots of glue 51, 53 are placed on one side of frontof header 18 and the header 18 is folded so that first and secondoval-shaped dots of glue 51, 53 cover and are glued or otherwise securedto respective first and second oval-shaped partially scored portions 47,49. Mandrel 303, which may be reciprocating, may be used in combinationwith first sealer 302 to assure a square shape of the semi-rigidcontainer 12 and further to assure reliable gluing by dots 51, 53.Alternately, other methods of attaching header 18 to the sides of theformed semi-rigid container 12 may be used as previous described.Thereafter, inverted package 10 is filled from filler 304. First folder306 folds along first and second interior horizontal folds 46, 46′, 48and seals to form fin seal 52 and triangular ears 58, 60 as shown inFIG. 4A and 4B. First folder 306 may be implemented as an invertedconfiguration of the band sealer 310 shown in FIGS. 13 and 14.Polytetrafluoroethylene belts 312, 313 grip the material of the fin seal52 and heated seal bars 314, 315 perform the sealing operation betweenthe front and rear panels 13, 15 thereby completing the fin seal 52.First folder 306 may also utilize adhesive for closing the bottom of thepackage 10. Second folder 308 folds the fin seal 52 flush to the package10 and seals the fin seal 52 to the package 10. Third folder 309 sealstriangular ears 58, 60 to the bottom of the package 10 (shown in solid)or to the first and second gusseted sides 34, 36 of semi-rigid container12 (shown in phantom). It may be preferred that the triangular ears 58,60 be sealed to the bottom of the package 10 for aesthetic purposes andto reduce the possibility of the consumer opening the bottom of thepackage 10. The semi-rigid container 12 may have different bottomfolding sections and different ways of folding these sections. Inalternative embodiments, the packages 10 are filled at a later stage, orare maintained in a continuous chain with perforated lines attaching thecross seals between adjacent packages 10 and stacked in a zig-zagconfiguration. In another alternative, the semi-rigid container 12 isnot inverted. After the bottom of the container is formed, thesemi-rigid container 12 is filled through the top as describedhereinafter with respect to FIGS. 21A-C.

FIG. 15A illustrates, in phantom, two possible positions of an optionalhandle 62 or 62′. One handle 62 may be sealed or otherwise formed on theside of header 18. Alternatively, a handle 62′ may be sealed orotherwise formed on front panel 13 of package 10.

FIG. 15B illustrates, in perspective, an extended header 18 with anaperture 63 therethrough, thereby forming a handle.

FIG. 16 illustrates an embodiment of header 18 wherein the fold betweenthe first and second sidewalls 20, 22 of header 18 includes a line ofweakness 72 (which may include perforations, laser scored lines, tearbeads, tear notches, linear tear films, or similar structures, and maybe configured as multiple lines) in place of, or in conjunction with,closure 24. Similarly, element 72 may be implemented as a linear tearline. This provides for a header 18 which can be opened by the consumer,but not reclosed. Similarly, FIG. 17A illustrates an embodiment ofheader 18 wherein sidewalls 20, 22 are provided as separate pieces witha peel seal 64 (typically pre-activated) therebetween. Element 64 couldlikewise be implemented as a tear tape or a pinch-grip zipper.

FIG. 18 illustrates a cross-section of an embodiment of semi-rigidcontainer 12 wherein front and rear panels 13, 15 are joined at one endby first gusseted side 34 and directly joined to each other at the otherend at point 36′ thereby eliminating second gusseted side 36 andproviding a triangular cross section which may be advantageous forpouring.

FIG. 19A illustrates an embodiment of a header 18 wherein first andsecond sidewalls 20, 22 are sealed or otherwise joined to each otheralong a portion 66 of the top edge, with a zipper 24, including firstand second profiles 25, 27, providing a reclosure along the remainder ofthe top edge. Typically, portion 66 is formed by sealing together asection of the zipper or the cross-seal 23 is extended across the header18, leaving only a small section open for pouring out the contents.Similarly, FIG. 19B illustrates an embodiment of header 18 wherein ashortened zipper segment 24′, configured as a fitment, is inserted intothe seal 66 between first and second sidewalls 20, 22 in a configurationadapted to locking after pouring of contents.

FIG. 20 illustrates an embodiment of header 18 including a funnelportion 67 created by forming diagonal seals and cut-outs to the doublefolded zipper film. Access to the funnel portion 67 is provided byzipper 24. The funnel portion 67 would be extended through header 18 fordispensing product therefrom.

FIG. 21A illustrates an embodiment with top-filling, wherein, firstsidewall 20 of header 18 is sealed, glued or attached to the semi-rigidcontainer 12. Prior to the sealing, gluing, or other attachment ofsecond sidewall 22 of header 18 to semi-rigid container 12, fillingapparatus 400 inserts the contents into the package. Thereafter, thesecond sidewall 22 is attached or sealed back to semi-rigid container 12by sealer 402. Alternately, as shown in FIG. 21B, a zipper flange 27′can be left unattached from its corresponding sidewall 22 and theproduct is filled by filler between the flange 27′ and the sidewall 22.Thereafter, the flange 27′ and the sidewall 22 are attached together bysealer 402. In a further alternative embodiment shown in FIG. 21C, thetop of the film of header 18 is slit, the zipper (or reclosure) 24 isopened, product is filled through zipper 24 by filler 400, the zipper 24is reclosed and the slit edges of header 18 are resealed by sealer 402.However, if separate sheets of web material are used as in FIG. 8C,there is no need to slit the top of header 18.

FIG. 22 illustrates an embodiment of package 10 wherein a straw-aperture68 in header 18, typically initially being sealed but providing an easyopening for the consumer. FIG. 22 additionally illustrates the structureof the removable header portion 29 illustrated in FIG. 27H. Furtherillustrated in FIG. 22 is the attachment of a rigid support member 153to the side of second gusseted side 36, as well as the header structureillustrated and described with respect to FIG. 27H. Additionallyillustrated on FIG. 22 is printing on the header and printing on thecarton.

FIG. 23 illustrates an embodiment of header 18 wherein reclosure 24 isimplemented as a flanged zipper with a slider 70. Additionally, thewalls of header 18 include a tear line 72 (typically implemented as aline of weakness, such as perforations, laser scored lines, tear beads,tear notches, linear tear films, or similar structures, and may beconfigured as multiple lines) which is above the reclosure 24 in thefirst and second cross seals 21, 23, descending to the area between thetop of reclosure 24 and the seal lines 74 joining the zipper flanges andthe walls of header 18. Slider 70 operates in the conventional way,opening the zipper when moved in a first direction and closing thezipper when moved in a second direction, opposite to the firstdirection.

FIG. 24 illustrates an embodiment wherein header 18 is held in place bya cap 80. Cap 80 includes rectangular top 82 with side walls 84extending downwardly therefrom. The rectangular shape of cap 80 aids notonly in strengthening or reinforcing the package 10, but also helps thepackage 18 retain a rectangular cross section. Similarly, FIG. 25illustrates an embodiment of package 10 with band 86 holding down theheader 18. As previously described with respect to FIG. 22, the gussetedsides 35 or 36 may be provided with rigid support member 153. Top 82 andband 86 may be breakably attached to semi-rigid container 12, therebyproviding tamper evidence, if removed.

FIG. 26 illustrates an embodiment of package 10 with a rectangularsemi-rigid container 12 which has four sides 90, 91, 92, 93 therebyforming a square or rectangular shape which is free of gussets. Theheader 18 is glued, sealed or otherwise attached to flattened semi-rigidcontainer 12 by methods previously described so that cross-seal 21 isaligned with the corner or fold formed between sides 90, 93 andcross-seal 23 is aligned with the corner or fold formed between sides91, 92 (formed oppositely from the corner formed by sides 90, 93). Thisconfiguration allows the semi-rigid container 12, with the header 18attached, to lie flat prior to filling (that is, sidewalls 90 and 93 arepressed or folded flat against each other and sidewalls 91, 92 arepressed or folded flat against each other), similar to the previouslydescribed embodiments, however without requiring gussets. In the openconfiguration, as shown in FIG. 26, the zipper 24 extends diagonallyacross the open top of the semi-rigid container. Similar configurationscould be achieved with packages with an even number of sides, greaterthan four.

Thus the several aforementioned objects and advantages are mosteffectively attained. Although preferred embodiments of the inventionhave been disclosed and described in detail herein, it should beunderstood that this invention is in no sense limited thereby and itsscope is to be determined by that of the appended claims.

1-18. (canceled)
 19. A method for filling a package including a rigid orsemi-rigid container portion and a polymeric header, including the stepsof: opening the rigid or semi-rigid container portion in an invertedconfiguration thereby creating a volume for contents therein; insertingcontents through an open bottom of the inverted rigid or semi-rigidcontainer portion; closing the bottom of the inverted rigid orsemi-rigid container portion thereby forming a seal.
 20. The method ofclaim 19 further including the step of releasably attaching ends of theheader to sides of the rigid or semi-rigid container portion.
 21. Themethod of claim 19 wherein the seal is a fin seal, and further includingthe steps of: folding the fin seal against the bottom of the invertedrigid or semi-rigid container portion; and sealing portions of thebottom of the inverted rigid or semi-rigid container portion.
 22. Themethod of claim 21 wherein the step of closing the bottom furthercreates ears extending from the bottom of the inverted rigid orsemi-rigid container portion.
 23. The method of claim 22 furtherincluding the step of sealing the ears against sides of the rigid orsemi-rigid container portion.
 24. The method of claim 22 furtherincluding the step of sealing the ears against the bottom of the rigidor semi-rigid container portion.
 25. The method of claim 21 wherein thestep of closing the bottom is performed by a band sealer.
 26. A methodfor filling a package including a rigid or semi-rigid container portionand a polymeric header, including the steps of; opening the rigid orsemi-rigid container portion thereby creating a volume for contentstherein; closing the bottom of the rigid or semi-rigid container portionthereby forming a seal; inserting contents through an opening betweenthe rigid or semi-rigid container portion and the polymeric header; andsealing the opening between the rigid or semi-rigid container portion.27. The method of claim 26 wherein the seal is a fin seal, and furtherincluding the steps of: folding the fin seal against the bottom of therigid or semi-rigid container portion; sealing portions of the bottom ofthe rigid or semi-rigid container portion.
 28. The method of claim 27wherein the step of closing the bottom further creates ears extendingfrom the bottom of the rigid or semi-rigid container portion.
 29. Themethod of claim 28 further including the step of sealing the earsagainst sides of the rigid or semi-rigid container portion.
 30. Themethod of claim 28 further including the step of sealing the earsagainst the bottom of the rigid or semi-rigid container portion.
 31. Amethod for filling a package including a rigid or semi-rigid containerportion and a polymeric header, including the steps of opening the rigidor semi-rigid container portion thereby creating a volume for contentstherein; closing the bottom of the rigid or semi-rigid container portionthereby forming a seal; inserting contents through an opening in thepolymeric header; and sealing the opening in the polymeric header. 32.The method of claim 31 wherein the seal is a fin seal, and furtherincluding the steps of: folding the fin seal against the bottom of therigid or semi-rigid container portion; sealing portions of the bottom ofthe rigid or semi-rigid container portion.
 33. The method of claim 32wherein the step of closing the bottom further creates ears extendingfrom the bottom of the rigid or semi-rigid container portion.
 34. Themethod of claim 33 further including the step of sealing the earsagainst sides of the rigid or semi-rigid container portion.
 35. Themethod of claim 33 further including the step of sealing the earsagainst the bottom of the rigid or semi-rigid container portion. 36-51.(canceled)
 52. A method for forming and filling a package, includingsteps for forming and steps for filling, wherein: the steps for formingincluding: providing a source of flat, folded rigid or semi-rigidcontainer portions; providing a source of web material; providing asource of reclosure material; and attaching the web material, with thereclosure material attached thereto, to the top of the rigid orsemi-rigid container portions thereby forming a header; forming seals inthe web material between adjacent container portions; and the steps forfilling including: opening the rigid or semi-rigid container portion inan inverted configuration thereby creating a volume for contentstherein; inserting contents through an open bottom of the inverted rigidor semi-rigid container portion; closing the bottom of the invertedrigid or semi-rigid container portion thereby forming a seal.
 53. Themethod of claim 52 wherein the steps for filling further include thestep of releasably attaching ends of the header to sides of the rigid orsemi-rigid container portion.
 54. The method of claim 52 wherein thesteps for forming further includes cutting the web material betweensuccessive rigid or semi-rigid container portions.
 55. The method ofclaim 52 wherein the steps for filling and the steps for forming areperformed by an integral piece of apparatus.
 56. The method of claim 52wherein the steps for filling and the steps for forming are performed byseparate apparatus.
 57. The method of claim 52 wherein the steps forfilling and the steps for forming are performed in the same geographiclocation.
 58. The method of claim 52 wherein the steps for filling andthe steps for forming are performed in different geographic locations.59. The method of claim 52 wherein the steps for filling and the stepsfor forming are performed simultaneously.
 60. The method of claim 52wherein the steps for filling and the steps for forming are able to beperformed independently.